Soap powder



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Patented Apr. 30, 1935 PATENT OFFICE SOAP POWDER Carleton Ellls, Montclair, N. J assignor to Standard Oil Development Company, a corporation of Delaware No Drawing. Application April 7, 1932,

Serial No. 603,897

8 Claims. (Cl. 87-46) This invention relates to soap powders and similar soap materials and the process of making same and particularly to a dry pulverulent soap powder intended for cleaning and other similar purposes.

The invention involves the manufacture of soap powders and similar soap materials without the use of a large quantity of water for the purpose of saponification, and by a method which brings about the direct combination of soap stock and alkali thus forming a soap powder which is light and fluffy and can be easily ground to a fine powder.

One of the materials used in the making of such soap powders is the fatty acids derived by the oxidation of parafiin wax by means of strong nitric acid, air, oxygen, or oxidizing gases. This oxidation is generally carried out at temperatures corresponding to the melting point of the waxes, or higher; and preferably in the presence of catalysts such as previously oxidized wax, manganese and cobalt resinates, barium cinnamate and the like, mixtures of these acids, or other appropriate catalysts. Besides the acids thus obtained by the oxidation of paraffin waxes, including petroleum waxes, the acids formed on the oxidation of other mineral waxes can be used, such as those from petrolatum, ceresin, ozocerite, Palembang wax, slop wax, wax-tailings, and in some instances Montan wax. Also the acids obtained by the oxidation of heavy petroleum oils and similar substances.

Furthermore these acids from petroleum or mineral products may be used alone or they may be mixed with oleic acid, stearic acid, distilled cottonseed oil acids or other natural fat soap stocks. Instead of using the mixed acids derived from petroleum or other mineral waxes I may effect a partial separation, for example, by distilling these acids under reduced-pressures and dividing them into several fractions and use these fractions. The initial fraction should contain acids having 9 to 11 carbon atoms, while the remaining fractions would contain acids corresponding to larger numbers of carbon atoms such as 12 to 18.

The soap powders or soap materials made from the lower fractions will be of a softer nature than those products made from the higher fractions. Those fractions which contain acids in stearic range, that is 17 or 18 carbon atoms, generally give the harder particles of soap product. By the use of one fraction, or mixtures of these fractions as desired, I may obtain soap products of a harder or softer nature.

I may also effect a partial separation of the mixed fatty acids by filtration, thus separating at any desired temperature the acids which are liquids from those which are solids. Either the liquid acids or the solid acids, or various mixtures of them, may be used in making the soap product.

Fillers and abrasives may also be used, particularly with the products from the more liquid acids. Examples of such substances are pumice powder and silex; also softer materials of the polishing type such as tripoli and infusorial earths. Another ingredient which could be used is vegetable ivory dust, of which large quantities ,are available from the button industry. This latter material cleans without scratching. The addition of these fillers and abrasives may take place during the process of making the soap product, or they may be mixed in afterwards.

Wetting agents may also be incorporated in I these soap powders or soap materials, for example, in the proportions illustrated below. Examples of such agents are the sulfonic acids or sulfonates formed in the treating of petroleum distillates with sulfuric acid. acids or their salts may be readily obtained from both the acid treated oils and the acid sludge. Many types of wetting agents obtained from other sources may be used also.

One process which can be used in the prepara- Example 1.-l part by weight of the mixed fatty acids derived by the oxidation of petroleum wax was mixed with 10 parts by weight of dry sodium carbonate (soda ash), and the mixture heated with constant stirring to about 250 F. The dry powder so obtained was nearly white in color and can be used as a detergent.

Example 2.The same quantities of ingredients were employed as in Example 1, and just enough water added to obtain a pasty mass.

This mixture was then heated to about 250 F.

Example 3.-l part by weight of the mixed fatty acids derived by the oxidation of petroleum wax and 1.5 parts by weight of dry sodium carbonate (soda ash) were mixed and heated to These sulfonic Cal about 200 F., with constant stirring. This product can be used as a detergent.

Example 4.Incorporation of the wetting agent was made in the following manner. 1 part by weight of the mixed fatty acids derived by the oxidation of petroleum wax was mixed with 4 parts by weight of sodium carbonate, and then heated. To 4 parts by weight of this soap product was added 1 part by weight of the sodium salts of low molecular weight sulfo-acids derived from the sludges obtained in treating petroleum distillates with sulfuric acid these sodium salts were the wetting agents. The mixture was thoroughly ground to secure a homogeneous product.

Example 5.--To 2 parts by weight of the soap product, prepared as in Example 4, was added 1 part by weight of the sodium salts of the mixed sulfo-acids derived from sludge obtained in treating petroleum distillates with sulfuric acid; these sodium salts being the wetting agents. The mixture was thoroughly ground to secure a homogeneous mixture.

Example 6.A soap powder was made by using 1 part by weight of the mixed fatty acids derived by the oxidation of petroleum wax, 1 part by weight of oleic acid, and 8 parts by weight of sodium carbonate (soda ash).

Example 7.The mixed fatty acids derived by the oxidation of petroleum wax were separated by filtration at 55-60 F. into liquid acids and solid acids. A soap product was made using 1 part by weight of the liquid acids and 5 parts by weight of sodium carbonate.

Example 8.-A soap powder was made by using 1 part by weight of liquid fatty acids obtained in Example '7, 6 parts by weight of sodium carbonate (soda ash) and 3 parts by weight of finely ground tripoli earth. I

Example 9.-A soap powder was made by using 1 part by weight of the solid fatty acids obtained in Example 7, and 5 parts by weight of sodium carbonate (soda ash).

Example 10.-A soap powder was made by using 1 part by weight of the solid fatty acids obtained in Example 7, 1 part by weight of distilled cottonseed oil fatty acids. and 8 parts by weight of sodium carbonate (soda ash).

Example 11.A soap powder was made by using 1 part by weight of the mixed fatty acids derived by the oxidation of petroleum wax, 1 part by weight of distilled cottonseed oil fatty acids, and 5 parts by weight of sodium carbonate (soda ash). 5 parts by weight of the soap powder so obtained was mixed with 2 parts by weight of vegetable ivory dust and the mixture well ground to secure a homogeneous product.

Example 12.-A soap powder was made by using 1 part by weight of the mixed fatty acids derived by the oxidation of petroleum wax, 1 part by weight of distilled cottonseed oil fatty acids, 6 parts by weight of sodium carbonate (soda ash), and 2 parts by weight of finely ground infusorial earth. It will be seen from the above examples that the wetting agent or the tiller always represents a minor proportion of the finished soap powder.

While I have given examples of the preparations of soap powder and similar soap materials I do not wish to limit myself to the alkali used, the proportions of the ingredients, or the ternperatures therein mentioned; as other alkalies, such as potassium carbonate, may be substituted for the sodium carbonate, or the proportions by weight in which the ingredients are mixed may be varied at will, and the temperature to which the mixture may be heated will vary with the proportions of ingredients used and the type of fatty acids employed.

The soap products so obtained can be used in any of the general cleaning processes for which soap materials of this type are applicable, such as the cleaning of porcelain and metallic ware, glassware, towels, floors, and in other ways.

I claim:

1. A detergent, consisting of a soap powder formed by heating and stirring a mixture of fatty acids, containing approximately 10 to 18 carbon atoms and derived by the oxidation of a substance of the class consisting of mineral hydrocarbon waxes and petroleum, with a substantially dry alkaline saponification agent of the class consisting of sodium carbonate and potassium carbonate to cause saponification of said acids.

2. A detergent, according to claim 1, in which said saponification is conducted with an excess of alkali carbonate.

3. A detergent, according to claim 1, containing in addition a minor proportion of an alkali metal petroleum acid sludge sulfonate.

4. A detergent, according to claim 1, in which the fatty acids used for said saponification consist of a distillate fraction of the said mixture of fatty acids.

5. A detergent, according to claim 1, in which the fatty acids used for said saponification consist of a fraction obtained by partial solidification and separation of liquid and solid fractions of said mixture of fatty acids.

6. A detergent, consisting of a soap powder containing as a major ingredient the saponification product with an alkali carbonate of a mixture of fatty acids containing, approximately, 10 to 18 carbon atoms and obtained by oxidation of a substance of the class consisting of mineral waxes.

'7. A detergent, consisting of a soap powder containing as a major ingredient the saponification product with an alkali carbonate of a mixture of fatty acids containing, approximately, 16 to 18 carbon atoms and obtained by oxidation of a substance of the class consisting of mineral waxes.

8. A water soluble soap in powdered form consisting at least largely of a mixture of alkali metal soaps of a complex mixture of fatty acids containing approximately 16 to 18 carbon atoms and derived by the oxidation of a substance of the class consisting of mineral hydrocarbon waxes.

CARLETON ELLIS. 

